Continuous wash &amp; plush laminate

ABSTRACT

A method for producing an improved washed and plushed upholstery fabric in a continuous process includes the provision of a soft, dimensionally stable, nonwoven fabric backing. After the chemical application of an anti-migrant and softener, the fabric is washed in a rope form, opened and de-twisted. After the fabric is rewound and further coatings are applied, an adhesive is applied to hold a nonwoven web to the previously prepared fabric in a rewinding process. The fabric is then subjected to a steam flow process to enhance the fabric texture and reduce the width of the fabric.

This application claims the priority date of U.S. Provisional No.60/552,564 filed Mar. 12, 2004.

FIELD OF THE INVENTION

This invention relates to production of washed and plushed upholsteryfabrics, primarily chenille containing, and the application of backingmaterials.

BACKGROUND OF THE INVENTION

Wash and Plush fabrics have been popular for some time. Their mainadvantage has been relatively low cost and moderate quality. The typicalproduction involves a batch process. Although some attempts have beenmade to enhance the fabric by the application of latex backing, this hasbeen detrimental to the hand of the fabric. What is needed is a moreeconomical continuous process for manufacturing wash and plush fabrics,wherein the process can apply nonwoven backing material to a surface ofthe fabric.

BRIEF DESCRIPTION OF THE INVENTION

An economical method for producing an improved washed and plushedupholstery fabric comprises a continuous process including the provisionof a soft, dimensionally stable, nonwoven fabric backing. The processinvolves steps for the chemical application of an anti-migrant andsoftener. The fabric is then washed in a rope form, opened under thecontrol of a load cell and de-twisted. The fabric is then rewound andfurther coatings are applied. An adhesive is applied while the width ofthe fabric is maintained by a pin frame. A nonwoven web is applied tothe previously prepared fabric in a rewinding process. The fabric isthen subjected to a steam flow process to enhance the fabric texture andto reduce the width of the fabric.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS

The present invention provides continuous process for fabrication of anovel washed and plushed upholstery fabric having superior fabricelongation stability, superior recovery properties, less yarn raveling,and improved sewing and cut-ability. One aspect of the invention is theprovision of a soft, dimensionally stable, nonwoven fabric backing in aseries of unique process steps.

The process begins with the chemical application of an anti-migrant andsoftener sprayed preferably upon a rayon or an acrylic fabric in openwidth. The rate of application is between 50 and 300 ml/min. For rayon arate of 300 ml/min is optimal. For acrylic a rate of 100 ml/min isoptimal. The fabric is then subjected to a continuous wash in a ropeform. Compared with prior batch processes, this treatment produces amore repeatable effect. The rope is then opened under the control of aload cell, which controls the rate of operation, and de-twisted back toits full width. The fabric is then rewound to its open width. Furthercoatings are applied at a low coating weight. Where the material ishighly textured, the tension is maintained at a low value to prevent theloss of texture.

An adhesive powder is then applied at a speed of 15-20 yards per minute.For highly textured fabrics the amount of powder is kept below about 1oz/lin. yd to prevent a harsh hand. For light weigh materials it isoptimal to provide about 4 oz/lin. yd to provide bulk to the fabric. Thewidth of the fabric, ranging from 55″ to 110″ is maintained by a pinframe.

A polypropylene, polyester or blended nonwoven web in the weight rangeof 0.25 to 5 ounces per square yard is unwound and then applied to thepreviously prepared fabric in a rewinding process. The web may be eitherwhite or black.

The fabric is then subjected to a steam flow process at a rate of about26 yards per minute. This provides enhancement of the fabric texture andreduces the width to between 55 and 110 inches. During this process thefabric is transported on a belt without tension. The fabric is then flatfolded in open width, inspected and packaged.

As a result of this processing, a significant cost reduction is achievedby a continuous process that avoids the batch processing of the priorart, as well as providing an improved product.

Although particular embodiments of the invention have been described, itwill be apparent to persons of ordinary skill in the relevant arts thatthe invention may be practiced by modifications that do not depart fromthe substance of the invention. Accordingly the scope of protection ofthis patent should not be limited to the disclosed embodiments butshould be determined from the following description of the invention interms of claims.

1. A method for producing a washed and plushed upholstery fabric in acontinuous process comprising the steps of: a. Spraying a base fabricwith an anti-migrant and/or softener in open width. b. Subjecting thefabric to a continuous wash in a rope form. c. Opening the rope form,wherein the fabric is de-twisted back to its full width. d. Rewindingthe fabric to its open width. e. Applying further coatings at a lowcoating weight. f. Applying an adhesive, while maintaining the width ofthe fabric by a pin frame. g. Unwinding and applying in a rewindingprocess a nonwoven web. h. Subjecting the fabric to a steam flow processwhile transporting the fabric on a belt without substantial tension. 2.The method for producing a washed and plushed upholstery fabric in acontinuous process of claim 1 wherein the rate of spraying of step a isat a rate of application of between 50 and 300 ml/min.
 3. The method forproducing a washed and plushed upholstery fabric in a continuous processof claim 2 wherein the fabric is rayon and the rate of application isapproximately 300 ml/min.
 4. The method for producing a washed andplushed upholstery fabric in a continuous process of claim 2 wherein thefabric is an acrylic and the rate of application is approximately 100ml/min.
 5. The method for producing a washed and plushed upholsteryfabric in a continuous process of claim 1, wherein step c is performedunder the control of a load cell that controls the rate of operation ofthe process step.
 6. The method for producing a washed and plushedupholstery fabric in a continuous process of claim 1, wherein the fabricis highly textured and during step e tension on the fabric is maintainedat a low value to prevent the loss of texture.
 7. The method forproducing a washed and plushed upholstery fabric in a continuous processof claim 1, wherein the adhesive is a powder.
 8. The method forproducing a washed and plushed upholstery fabric in a continuous processof claim 7, wherein the adhesive powder is applied at a speed of 15-20yards per minute.
 9. The method for producing a washed and plushedupholstery fabric in a continuous process of claim 1 wherein the fabricis highly textured and the adhesive is applied below the amount of about1 oz/lin. yd.
 10. The method for producing a washed and plushedupholstery fabric in a continuous process of claim 1 wherein the fabricis a light weight fabric and the adhesive is applied above the amount ofabout 4 oz/lin. yd.
 11. The method for producing a washed and plushedupholstery fabric in a continuous process of claim 1, wherein thenonwoven web is a polypropylene plastic.
 12. The method for producing awashed and plushed upholstery fabric in a continuous process of claim11, wherein the weight range of the nonwoven web is 0.25 to 5 ounces persquare yard.
 13. The method for producing a washed and plushedupholstery fabric in a continuous process of claim 1, wherein thenonwoven web is a polyester.
 14. The method for producing a washed andplushed upholstery fabric in a continuous process of claim 13, whereinthe weight range of the nonwoven web is 0.25 to 5 ounces per squareyard.
 15. The method for producing a washed and plushed upholsteryfabric in a continuous process of claim 1, wherein the nonwoven web is ablend of polyester and polypropylene.
 16. The method for producing awashed and plushed upholstery fabric in a continuous process of claim15, wherein the weight range of the nonwoven web is 0.25 to 5 ounces persquare yard.
 17. The method for producing a washed and plushedupholstery fabric in a continuous process of claim 1, wherein the steamflow process is operated at a rate of about 26 yards per minute.
 18. Themethod for producing a washed and plushed upholstery fabric in acontinuous process of claim 1, wherein the steam flow process reducesthe width of the fabric to between 55 and 110 inches.
 19. The method forproducing a washed and plushed upholstery fabric in a continuous processof claim 1, further comprising the step of flat folding the fabric inopen width.
 20. A method for producing a washed and plushed upholsteryfabric in a continuous process comprising the steps of: a. Spraying abase fabric with an anti-migrant and/or softener upon a rayon or anacrylic fabric in open width, wherein for rayon the rate of applicationis about 300 ml/min, whereas for acrylic the rate of application isabout 100 ml/min is optimal. b. Subjecting the fabric to a continuouswash in a rope form. c. Opening the rope form under the control of aload cell, which controls the rate of operation, wherein the fabric isde-twisted back to its full width. d. Rewinding the fabric to its openwidth. e. Applying further coatings at a low coating weight, wherein thematerial is highly textured, and the tension is maintained at a lowvalue to prevent the loss of texture. f. Applying an adhesive powder ata speed of 15-20 yards per minute, wherein for highly textured fabricsthe amount of powder is kept below about 1 oz/lin. yd and for lightweigh materials the amount of powder is kept at about 4 oz/lin. yd whilemaintaining the width of the fabric, by a pin frame. g. Unwinding andapplying in a rewinding process a polypropylene, polyester or blendednonwoven web in the weight range of 0.25 to 5 ounces per square yard. h.Subjecting the fabric to a steam flow process at a rate of about 26yards per minute, wherein the fabric width is reduced to between 55 and110 inches, while transporting the fabric on a belt without substantialtension.